Re: GTV6 (or any Alfa for that matter) Door locks and keys

["Obie Fayth" <bibendum59@domain.elided>]

Robert,
     I have re-keyed the locks on my gtv6 before. It was a couple of years 
ago, but I'll see if I can remember the main things. First of all, yes it is 
possible, although it is kind of a pain and depending on how much you value 
your time it might be better to just buy a good used set that matches, or a 
car that comes with matching locks ;)
     The first thing you need to do is decide if you have enough of the 
correct tumblers to re-key your locks. If I remember correctly each lock has 
two sets of five tumblers. 10 tumblers/lock * 3 locks = 30 tumblers per car. 
The tumblers come in three sizes and you can deduce the sizes by looking at 
the keys. No cut, shallow cut and deep cuts in the key correspond to short, 
medium and tall tumblers. I would lay the three keys on the table and make a 
little map to record the layout and sizes for each key. For ex. a key may 
have the following layout (from tip to handle):
M M
T S
S T
M S
M M

Map out all three of your keys. You only have to re-key two of your locks, 
so pick the one you want to leave as is (driver's door is safest). We'll 
call this one the master. Add up the number of each length tumbler used in 
the other two locks and see if you have enough tumblers from the other two 
locks. In the example I need 3 short, 5 medium and 2 tall tumblers to make a 
lock match this key. If you have 6 short, 10 medium and 4 tall tumblers in 
the other two locks you are set, if not you can try picking another master, 
buy some spare locks, or if you have too many big tumblers and not enough 
smaller ones you can grind some of them down. I'm sure the locksmiths out 
there just cringed ;) It works, but it is easy to get carried away and mess 
it up.
     Next you need to remove whatever locks you are going to rekey from the 
car. Hatch is easy, on the doors you must unbolt the handle. The doors have 
a small piece of cast alloy that surrounds the lock cylinder which is 
riveted in place and needs to be removed. You can carefully hammer back the 
rivets and remove the piece (use caution the cast piece is easy to break). 
The hatch lock has a small metal pin that holds it in its sleeve. Remove the 
pin with a pair of needle nose pliers and slide the cylinder free.
     The tumblers on each lock are held in place by two thin metal covers on 
either side that slide in place. You need a small pick to slowly and 
carefully slide the covers off towards the front of the lock. Under the 
covers are springs and under those the tumblers. Dissassemble the locks, 
shuffle around the tumblers and test out the key. If it doesn't turn freely, 
try swaping around some of the same sized tumblers (there could be slightly 
differences). If you have to grind down a tumbler, use sandpaper and make 
sure to check it frequently. You don't want to take it down too far. When 
reassembling, get the metal cover started in its track, drop the first 
tumbler in place along with a spring. Compress the spring and slide the 
cover back to cover it. Repeat for the rest of the tumblers on each of the 
two sides. Re-assembly, as they say, is the reverse of removal. Lube the 
locks with a little graphite. When you go to reattach the alloy pieces you 
can carefully expand the rivets again or use a punch if needed. If there 
isn't enough of the post left you can try some epoxy. One of mine was like 
that when I took it apart and it held quite well.
     After you have put the locks back together and in the car the good news 
is you should have one key that opens all three locks. Of course the bad 
news is that you have ONLY one key that opens all three locks so now you can 
begin the search for the locksmith who can make a duplicate.

Good luck all,
-Obie
in Tacoma, Wa
w/ assorted alfas



>Date: Wed, 3 Apr 2002 15:45:15 -0700
>From: "Robert Savi at TechStyle Computers, Inc" 
><savi@domain.elided>
>Subject: GTV6 (or any Alfa for that matter) Door locks and keys
>
>The PO of my GTV6 changed the door locks as they broke.  Unfortunately each
>door (of the three) has different keys.  Any way to key them alike?  Any
>advice is appreciated.
>
>By the way, the torsion bars finally came out!!!!!!!!!!  I'll write up some
>pointers in a future posting.
>
>Regards,
>
>Robert C. Savi


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